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The Manufacturing Backbone Global Brands Rely On

From electronics assembly and wire harness manufacturing to box build, electrical panels, and testing, we delivers full-spectrum manufacturing under one roof, with the engineering depth and quality systems that precision-critical industries demand.

Trusted by teams that can't afford failure

25
+
Years of Experience
100
+
Clients worldwide
500
+
Projects Delivered
ISO
9001 & 14001 certified

Every manufacturing capability. One accountable partner.

Seven specialised manufacturing services delivered as one seamlessly integrated programme when your product needs them together

PCB Assembly manufacturing

SMT, through-hole, and mixed-technology PCB assembly with full traceability, IPC-compliant processes, and multi-stage inspection across all volume tiers.
Explore PCB assembly

Manufacturing process development (DFM)

DFM analysis and process engineering that validates your design for manufacturability before production begins, reducing variability, rework, and cost at scale.
Explore DFM

Electrical panel & process control subsystems

Design and assembly of electrical control panels and process control subsystems built to specification, tested for reliability, and compliant with relevant safety standards.
Explore electrical panels

Cable & wire harness manufacturing

Custom wire and cable harness assemblies engineered for precision, durability, and compliance from single prototypes to high-volume production across automotive, industrial, and energy applications.
Explore wire harness

Prototype & post-production support

From rapid prototyping and pilot runs before launch, to engineering change order management and ongoing production support after - we stay with your product for its full manufacturing lifecycle, not just the initial run.
Explore prototype & post-production support

Finished product manufacturing (box build)

Complete box-build assembly integrating PCBs, wire harnesses, mechanical enclosures, and sub-assemblies into a fully tested, field-ready finished product.
Explore box build assembly

Testing & quality assurance

ICT, functional testing, AOI, X-ray inspection, and burn-in - multi-stage quality protocols ensuring every unit meets spec before it leaves the facility.
Explore testing & quality
PCB Assembly manufacturing
SMT, through-hole, and mixed-technology PCB assembly with full traceability, IPC-compliant processes, and multi-stage inspection across all volume tiers.
Explore PCB assembly
Manufacturing process development (DFM)
DFM analysis and process engineering that validates your design for manufacturability before production begins, reducing variability, rework, and cost at scale.
Explore DFM
Electrical panel & process control subsystems
Design and assembly of electrical control panels and process control subsystems built to specification, tested for reliability, and compliant with relevant safety standards.
Explore electrical panels
Cable & wire harness manufacturing
Custom wire and cable harness assemblies engineered for precision, durability, and compliance from single prototypes to high-volume production across automotive, industrial, and energy applications.
Explore wire harness
Prototype & post-production support
From rapid prototyping and pilot runs before launch, to engineering change order management and ongoing production support after - we stay with your product for its full manufacturing lifecycle, not just the initial run.
Explore prototype & post-production support
Finished product manufacturing (box build)
Complete box-build assembly integrating PCBs, wire harnesses, mechanical enclosures, and sub-assemblies into a fully tested, field-ready finished product.
Explore box build assembly
Testing & quality assurance
ICT, functional testing, AOI, X-ray inspection, and burn-in - multi-stage quality protocols ensuring every unit meets spec before it leaves the facility.
Explore testing & quality

The facility and systems behind the promise.

World-class manufacturing infrastructure built to deliver consistency, traceability, and quality at every volume tier.
Advanced SMT lines

Advanced SMT lines

High-speed, high-precision surface mount technology lines capable of handling complex, high-density board assemblies across all volume tiers.

Advanced SMT lines

AOI & X-ray inspection

ESD-controlled production environment

Dedicated wire harness production lines

Product assembly & box build facility

Full traceability systems

ISO-certified quality management system

Manufacturing expertise across 13+ industries.

We bring sector-specific process knowledge, compliance understanding, and application experience to every
programme not just capacity.
Automotive

Automotive

IPC Class 3, wire harness, full traceability
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Medical Devices

Medical Devices

Compliance-critical, cleanroom-compatible
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Telecom

Telecom

High-density assemblies, uptime-critical
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Renewable energy

Renewable energy

Thermal & environmental durability
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Consumer Electronics

Consumer Electronics

High-volume, cosmetic & functional quality
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Industrial

Industrial

Ruggedised, continuous-operation assemblies
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A manufacturing process built for zero surprises.

From programme kick-off to post-delivery support - every step is structured to protect quality, compress timelines, and keep you informed.
  • 1
    Programme onboarding
  • 2
    Line setup & tooling
  • 3
    Pilot run & first article inspection
  • 4
    Full-scale production
  • 5
    Quality gate & final sign-off
  • 6
    Delivery & ECO support

Programme onboarding

We onboard your programme with a full technical review - design files, BOM, quality standards, regulatory requirements, and volume targets. A dedicated programme manager is assigned, milestones are set, and every stakeholder is aligned before production planning begins.
Programme onboarding

Line setup & tooling

Our process engineers configure production lines, develop work instructions, and set up all required tooling, fixtures, and test equipment specific to your product. DFM inputs are finalised at this stage, locking the process before a single unit is built.
Line setup & tooling

Pilot run & first article inspection

A controlled pilot run is built and subjected to first article inspection (FAI) including validating process capability, workmanship standards, and test coverage at low volume before full production release. Any issues surface here, not on the production floor.
Pilot run & first article inspection

Full-scale production

Production runs at full volume with real-time quality monitoring, in-line inspection at every critical stage, and component-level traceability throughout. EMS, wire harness, box build, and panel assembly are coordinated as a single integrated programme not separate handoffs.
Full-scale production

Quality gate & final sign-off

Every finished unit passes our multi-stage quality gate - ICT, functional test, AOI, X-ray where required, and final visual inspection. Nothing is released for delivery without full quality sign-off and complete traceability documentation in place.
Quality gate & final sign-off

Delivery & ECO support

Units ship fully documented, labelled, and traceable. Post-delivery, our team manages engineering change orders (ECOs), field issue investigations, and ongoing production support, staying with your product for its full manufacturing lifecycle, not just the initial run.
Delivery & ECO support

Results that speak louder than claims.

Mission-critical ruggedised electronics programme — zero failures across operational deployment.

Mission-critical ruggedised electronics programme — zero failures across operational deployment.
Problem
A defence system integrator needed IPC Class 3 PCB assemblies and wire harnesses for a ruggedised communications unit requiring conformal coating, vibration and thermal cycling validation, and complete component-level traceability for procurement audit.
Solution
We built dedicated assembly and harness lines with 100% AOI, X-ray on all BGAs, HiPot testing, automated conformal coating, and environmental stress screening with full documentation packages maintained throughout for procurement audit readiness.
Outcome
Zero failures across operational deployment. Procurement audit passed with complete traceability records. Programme extended with JINST for the next system variant.
0 operational failures · audit passed · programme extended
Read The Full Case Study

IoT consumer product – 20,000 retail-ready units delivered in 10 weeks with zero 90-day returns.

IoT consumer product – 20,000 retail-ready units delivered in 10 weeks with zero 90-day returns.
Problem
A consumer IoT brand needed to ramp from validated prototype to 20,000 retail-ready finished products - PCB assembly, enclosure integration, firmware loading, and retail packaging within a 10-week window to meet a retail launch commitment.
Solution
We managed the full programme - PCB assembly, box build, firmware loading, functional test, and retail packaging with parallel workstreams compressing the timeline and weekly progress updates keeping the client informed throughout.
Outcome
20,000 retail-ready units delivered within the 10-week window. Zero returns in the first 90 days post-launch. Client rated JINST 5/5 for quality and communication on the programme.
20,000 units · 10 weeks · zero 90-day returns
Read The Full Case Study

Rolling stock control electronics — zero in-service failures across 3-year deployment.

Rolling stock control electronics — zero in-service failures across 3-year deployment.
Problem
A rolling stock OEM needed ruggedised control PCB assemblies and wire harnesses for an auxiliary power unit requiring conformal coating, vibration testing, HiPot testing, and full traceability for safety certification documentation.
Solution
We built dedicated assembly and harness lines with automated conformal coating, vibration stress screening, 100% HiPot testing, and complete unit traceability with certification-supporting documentation delivered with every production batch.
Outcome
Zero in-service failures across 3-year deployment. Safety certification accepted with complete manufacturing records. We retained for spare parts supply across the platform lifecycle.
0 in-service failures · certification accepted · lifecycle support retained
Read The Full Case Study

PTH to hybrid SMD redesign – 450-component BOM converted to 70% SMD for better stability and lower cost.

PTH to hybrid SMD redesign – 450-component BOM converted to 70% SMD for better stability and lower cost.
Problem
A client was running an ageing through-hole PCB design with a 450-component BOM facing higher assembly costs, larger board size, component availability challenges, and reliability limitations inherent to a fully leaded design.
Solution
We redesigned the entire PCB converting 70% of components from PTH to SMD to create a hybrid design, replacing components where better modern equivalents existed, and optimising the layout for improved thermal performance and assembly efficiency.
Outcome
Hybrid PCB delivered with improved stability, reduced assembly cost, and a more manufacturable design achieving the client's cost-down objective without compromising product performance.
450-component BOM · 70% SMD conversion · cost reduction achieved
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From import dependency to indigenous manufacturing — 100+ harness variants developed for a 5000 HP gas engine programme

From import dependency to indigenous manufacturing — 100+ harness variants developed for a 5000 HP gas engine programme
Problem
A PSU and private oil & gas client was dependent on imported wire harnesses for a 5000 HP gas engine system driving up costs and creating critical supply chain risk.
Solution
We reverse-engineered the harness, created full drawings and connection details, sourced domestic alternates to the same specification, and designed and manufactured 100+ harness variants entirely in-house.
Outcome
100+ harness variants developed and manufactured locally, reducing cost and eliminating supply dependency for a critical industrial system.
100+ harness variants · 5000 HP engine · full import substitution
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From recurring field failure to permanent fix: debugging a motor control PCB under pressure

From recurring field failure to permanent fix: debugging a motor control PCB under pressure
Problem
A motor control PCB managing both AC and DC motors on an industrial machine was failing intermittently in the field with no clear pattern, and no confirmed root cause behind the fault.
Solution
Our engineering team reproduced the failure in lab conditions, identified an underrated component as the root cause, revised the component rating, updated the PCB layout, and validated the fix before rollout.
Outcome
A validated two-part engineering fix: a corrective action for machines already deployed, and a permanent circuit and layout change carried into new production closing the failure at its root, not just its symptom.
Root cause confirmed in lab · circuit redesigned · validated before rollout
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Zero field failures across a 50,000-unit medical PCB programme with full regulatory audit compliance.

Zero field failures across a 50,000-unit medical PCB programme with full regulatory audit compliance.
Problem
A medical device OEM required IPC Class 3 PCB assemblies for a diagnostic product with zero field failure tolerance, full component-level traceability for DHR, and ISO 13485-aligned documentation throughout the production run.
Solution
We configured a dedicated assembly line with 3D SPI, 100% AOI, X-ray on all BGA joints, ICT, and functional test with DHR-supporting traceability records maintained at component level throughout both production runs.
Outcome
Zero field failures across 50,000 units. Client passed ISO 13485 audit with complete traceability records. First pass yield maintained above 99.8% across both runs.
0 field failures · 99.8% FPY · ISO 13485 audit passed
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Zero field failures across 50,000 medical PCB assemblies through multi-stage integrated testing.

Zero field failures across 50,000 medical PCB assemblies through multi-stage integrated testing.
Problem
A medical device OEM required IPC Class 3 PCB assemblies with zero tolerance for field failures and full unit-level traceability across a 50,000-unit production run with regulatory audit requirements.
Solution
We implemented a five-stage integrated test protocol - SPI pre-reflow, 100% AOI post-reflow, X-ray on all BGA joints, ICT, and functional test with unit-level traceability records maintained throughout.
Outcome
Outcome: Zero field failures across 50,000 units. Client passed regulatory audit with complete traceability records. First pass yield maintained above 99.8% across both production runs.
0 field failures · 99.8% FPY · full regulatory compliance
Read The Full Case Study

Reverse-engineered and redesigned full harness programme for a diesel generator system

Reverse-engineered and redesigned full harness programme for a diesel generator system
Problem
A diesel generator manufacturer needed their existing harness system redesigned and fully documented with no original drawings available, undefined current requirements, and a need to support both customisation and mass production going forward.
Solution
We reverse-engineered the system, defined all connection and current requirements, selected wire parameters, analysed sensor outputs and voltage drop across every sensing link, then designed full connection routing, bunching, electrical diagrams, and manufacturing drawings.
Outcome
Outcome: Complete harness programme delivered from system understanding and parameter definition through to electrical diagrams, manufacturing drawings, sample production, and full mass production support.
Full system redesign · end-to-end documentation · prototype to mass production
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End-to-end design and manufacture of a 15km-range drone communication box

End-to-end design and manufacture of a 15km-range drone communication box
Problem
A drone company needed a communication box capable of operating at up to 15km range covering radio control, telemetry, video, and payload protocols with no off-the-shelf solution available and no in-house electronics manufacturing capability to build it.
Solution
We designed and built the complete Base Com Box - hardware design, embedded software, drone communication protocol integration (ELRS, Crossfire, and others), and a fully tested, manufactured unit ready for mass production.
Outcome
A production-ready drone communication box with 15km operating range supporting RC, telemetry, video, and payload protocols designed, manufactured, tested, and scaled to mass production by us.
15km range · multi-protocol · design to mass production
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EOL component crisis averted – 18 months before it would have stopped production.

EOL component crisis averted – 18 months before it would have stopped production.
Problem
A key microcontroller in a long-running industrial product was approaching end-of-life — with 18 months of production remaining and no qualified alternative in the BOM. The client wasn't aware until JINST flagged it.
Solution
We executed a last-time buy to cover the remaining production forecast, simultaneously qualifying an alternative component and validating it through a full DFM and functional test cycle.
Outcome
Production continuity maintained with zero interruption. Alternative component qualified and in production 6 months before last-time buy stock was exhausted.
Zero production interruption · 18-month EOL risk resolved
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Avionics PCB assembly programme — zero failures through qualification testing and deployment.

Avionics PCB assembly programme — zero failures through qualification testing and deployment.
Problem
An avionics OEM needed IPC Class 3 PCB assemblies for a navigation module requiring fine-pitch BGA assembly, conformal coating, full component traceability, and thermal cycling validation to support certification submission.
Solution
We configured a dedicated line with 100% X-ray on all BGA joints, automated conformal coating, thermal cycling testing, and full chain-of-custody documentation with FAI reports and process validation records delivered with the first production batch.
Outcome
Zero failures through qualification testing. Certification documentation accepted first submission. Programme continued with JINST for subsequent platform variants.
0 qualification failures · certification accepted · programme extended
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From brief to 15km range – designing and manufacturing a drone communication box end-to-end

From brief to 15km range – designing and manufacturing a drone communication box end-to-end
Problem
A drone company needed a communication box capable of operating at up to 15km range covering radio control, telemetry, video, and payload protocols with no off-the-shelf solution available and no in-house electronics manufacturing capability to build it.
Solution
We designed and built the complete Base Com Box - hardware design, embedded software, drone communication protocol integration (ELRS, Crossfire, and others), and a fully tested, manufactured unit ready for mass production.
Outcome
A production-ready drone communication box with 15km operating range supporting RC, telemetry, video, and payload protocols designed, manufactured, tested, and scaled to mass production by us.
15km range · multi-protocol · design to mass production
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Industrial motor drive PCB programme – thermal validated, HiPot cleared, zero field returns.

Industrial motor drive PCB programme – thermal validated, HiPot cleared, zero field returns.
Problem
An industrial motor drive OEM was experiencing field failures on their previous supplier's assemblies traced to inadequate thermal interface material application and inconsistent HiPot testing. They needed a manufacturing partner with genuine power electronics discipline.
Solution
We conducted a DFM review identifying thermal and derating issues, implemented a dedicated assembly process with controlled TIM application, selective soldering, 100% HiPot testing, and burn-in at rated load before despatch.
Outcome
Zero field returns in first 12 months - versus 3.2% field failure rate with previous supplier. Client transferred full programme volume to us within 6 months of first delivery.
0% vs 3.2% field failure rate · full programme transferred
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Industrial IoT gateway from prototype to 5,000 deployed units in 12 weeks

Industrial IoT gateway from prototype to 5,000 deployed units in 12 weeks
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India. Solution
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
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EOL component crisis averted — programme kept running 3 more years without redesign.

EOL component crisis averted — programme kept running 3 more years without redesign.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
Read The Full Case Study

Zero field failures across 50,000 units — ISO 13485 audit passed with full traceability.

Zero field failures across 50,000 units — ISO 13485 audit passed with full traceability.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
Read The Full Case Study

Zero-defect wire harness delivery across a 50,000-unit automotive programme.

Zero-defect wire harness delivery across a 50,000-unit automotive programme.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
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5G base station PCB assembly — zero field failures across initial network deployment batch.

5G base station PCB assembly — zero field failures across initial network deployment batch.
Problem
A telecom OEM launching a new 5G base station module needed high-density BGA PCB assembly with signal integrity verification and functional testing on a compressed timeline to meet network operator deployment commitments.
Solution
We configured a dedicated line with 100% X-ray on all BGA joints, boundary scan testing, ICT, and full functional test completing NPI to production-ready in 8 weeks with test coverage designed for the specific signal paths of the board.
Outcome
Zero field failures across the initial deployment batch. Client met network operator deployment deadline. Programme scaled to full volume within 3 months of first production release.
0 field failures · 8-week NPI · on-time deployment
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Solar inverter wire harness programme – IP68 verified, zero field failures across first deployment season

Solar inverter wire harness programme – IP68 verified, zero field failures across first deployment season
Problem
A solar inverter OEM needed weatherproof wire harness assemblies for outdoor residential installations - UV-rated materials, IP68 overmoulded connectors, and HiPot verification across a 5,000-unit initial production run.
Solution
We designed and built dedicated harness assemblies with UV-resistant PVC jacket, low-pressure overmoulded connectors to IP68, and 100% continuity and HiPot testing with environmental stress screening on a representative sample before production release.
Outcome
Zero field failures across the first installation season. IP68 rating verified on 100% of units. Client expanded programme to 15,000 units for the following year.
0 field failures · IP68 verified · 5,000 units delivered
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Reverse engineering to mass production — complete harness redesign for a diesel generator system

Reverse engineering to mass production — complete harness redesign for a diesel generator system
Problem
A diesel generator manufacturer needed their existing harness system redesigned and fully documented with no original drawings available, undefined current requirements, and a need to support both customisation and mass production going forward.
Solution
We reverse-engineered the system, defined all connection and current requirements, selected wire parameters, analysed sensor outputs and voltage drop across every sensing link, then designed full connection routing, bunching, electrical diagrams, and manufacturing drawings.
Outcome
Complete harness programme delivered from system understanding and parameter definition through to electrical diagrams, manufacturing drawings, sample production, and full mass production support.
Full system redesign · end-to-end documentation · prototype to mass production
Read The Full Case Study

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